Lincoln Electric RANGER 300 D manual

RANGER 300 D and 300 DLX ™ OPERA TOR’S MANUAL IM571-A February, 2003 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv[...]

Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par[...]

vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Installation Instructions. .....................[...]

vii T ABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Kubota Engine Maintenance Schedule ..............................................[...]

A-1 INST ALLA TION RANGER 300 D AND 300 DLX A-1 TECHNICAL SPECIFICA TIONS - Ranger 300 D (K1522-1), Ranger 300 DLX (K1522-2) Make/Model Description Speed (RPM) Displacement Starting Capacities System Kubota 3 cylinder High Idle 3700 54.9 cu. in 12VDC battery Fuel: 10 gal. DH905 26.0 HP @ Low Idle 2150 (898 cc) (Group 45, 495 38 L Diesel Engine 3600[...]

A-2 INST ALLA TION RANGER 300 D AND 300 DLX A-2 SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. LOCA TION AND VENTILA TION Whenever you use the RANGER 300, be sure that clean cooling air can flow through the machine’s diesel engine and the machine case. Avoid dusty, dirty areas. Also, keep the machine a[...]

A-3 INST ALLA TION RANGER 300 D AND 300 DLX A-3 HIGH AL TITUDE OPERA TION It may be necessary to de-rate the welder output at higher altitudes. Derate the welder output 0.4% for every 100 ft. (30 m) above 500 ft. (150 m). Some engine adjustment may be required above 5,000 ft. (1,500 m). Contact a Kubota Service Representative. LIFTING The RANGER 30[...]

A-4 INST ALLA TION RANGER 300 D AND 300 DLX A-4 FUEL Fill the fuel tank with clean No. 2, diesel fuel only. Do not fill to the top of the filler neck to allow room for expansion. The RANGER 300 has a 10 gallon (38 liter) fuel tank with a top fill and fuel gauge mounted on the control panel. See the OPERATION and MAINTENANCE sections of this manual [...]

A-5 INST ALLA TION RANGER 300 D AND 300 DLX A-5 ELECTRICAL CONNECTIONS See Figure B.1 in the OPERATION section of this manual for location of the 115 and 230 volt recepta- cles, weld output terminals, circuit breakers and ground stud. MACHINE GROUNDING Because the RANGER 300 creates its own power from its diesel-engine driven generator, and if the [...]

A-6 INST ALLA TION RANGER 300 D AND 300 DLX A-6 AUXILIAR Y POWER RECEPT ACLES, PLUGS, AND HAND-HELD EQUIPMENT The control panel of the RANGER 300 features three auxiliary power receptacles: See Figure B.1. • Two 15 amp, 120 volt duplex (double outlet) recepta- cles. • One 50 amp 120/240 volt simplex (single outlet) receptacle. Through these rec[...]

A-7 INST ALLA TION RANGER 300 D AND 300 DLX A-7 Connection of Ranger 300 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AN[...]

B-1 OPERA TION RANGER 300 D AND 300 DLX B-1 GENERAL DESCRIPTION The RANGER 300 is a diesel-engine driven, multi- process AC and DC arc welder and AC power genera- tor for commercial and residential applications. As a generator it can supply up to 12,000 continuous watts of 120/240 volt, 60 Hz, single-phase AC power to operate AC power tools, batter[...]

B-2 OPERA TION B-2 ADDITIONAL FEA TURES RANGER 300 D (K1522-1): • One constant voltage wire-feed welding range - 80 to 200 amps. The wire feed setting permits the Ranger 300D to be used with the LN-25 Wire Feeder and .035, .045 or .068 NR®-211-MP Innershield electrodes. Limited MIG (GMAW) welding can also be done with .030 or .035 L-50 & L-5[...]

B-3 OPERA TION B-3 FIGURE B.1 OUTPUT P ANEL CONTROLS WELDER/GENERA TOR CONTROLS See Figure B.1 for the location of the following features: 1. OUTPUT RANGE SELECTOR: Selects continuous current output for constant current stick or TIG appli- cations (blue settings) and constant voltage wire feed applications (red settings). The amperages on the dial [...]

B-4 OPERA TION B-4 FIGURE B.2 DIESEL ENGINE CONTROLS ENGINE CONTROLS See Figure B.2 for the location of the following fea- tures: 1 . GLOW PLUG PUSH-BUTTON: Activates glow plugs to preheat engine for starting. 2. IDLER CONTROL SWITCH: The idler switch has two positions. “HIGH” and “AUTO”. When in “HIGH” ( ) position, the engine will run[...]

B-5 OPERA TION B-5 7. WATER TEMPERATURE LIGHT: Remains off under normal operating temperatures. If the red light turns on, the engine protection system will stop the engine. The light will remain on when the engine is over temperature and the “Engine” switch is in the “ON” position (engine not running) but will go off as the engine cools. 8[...]

B-6 OPERA TION B-6 NOTE: DO NOT allow the RANGER 300 to run out of fuel. If it does, you will have to bleed the injec- tion system. See the Maintenance section of this manual and the Engine Operators Manual for instructions on bleeding the fuel injection system. USE DIESEL FUEL ONL Y Purchase diesel fuel in quantities that will be used within 30 da[...]

B-7 OPERA TION B-7 BREAK-IN PERIOD Any engine will use a small amount of oil during its “break-in” period. For the diesel engine on the RANGER 300, break-in is about 50 running hours. Check the oil every four hours during break-in. Change the oil after the first 50 hours of operation, every 100 hours thereafter. Change the oil filter at the sec[...]

B-8 OPERA TION B-8 AC/DC STICK (CONST ANT CURRENT) WELDING 1. Remove the flange nuts from output terminals and place the work and electrode welding cables over the terminals. See Figure B.4. Replace and tight- en the flange nuts securely. Be sure the connec- tions are tight. 2. Select the appropriate electrode. See “Welding Tips 1" included [...]

B-9 OPERA TION B-9 AC/DC TIG (CONST ANT CURRENT) WELDING 1. Connect the K930-1 TIG Module to the RANGER 300. Follow the installation instructions provided with the kit. 2. Refer to the instruction manual with the TIG module (IM 528) for operation with a RANGER 300. And proper machine settings. 3. Set the RANGE switch to the appropriate setting for [...]

B-10 OPERA TION B-10 DC WIRE FEED WELDING (CV) WITH RANGER 300D 1. Connect an LN-25 with internal contactor to the Ranger 300D. 2. The only Innershield electrode recommended for use with the Ranger 300D is NR211MP. The elec- trode sizes and welding ranges that can be used with the Ranger 300D are shown in the following table: The Ranger 300 D is re[...]

B-11 OPERA TION B-11 RANGER 300 D AND 300 DLX SUMMAR Y OF WELDING PROCESSES AND MACHINE SETTINGS T ABLE B.3 SUMMAR Y OF WELDING PROCESSES FOR RANGER 300 DLX CONTROL CABLE & DIAGRAM IDLE MODE OUTPUT CONTROL SWITCH WELDING TERMINALS SWITCH ELECTRODE WHEN NOT WELDING TO START WELDING PROCESS STICK - CC CARBON ARC GOUGING - CC TIG - CC K930-1 TIG M[...]

B-12 OPERA TION B-12 RANGER 300 D AND 300 DLX SUMMAR Y OF WELDING PROCESSES AND MACHINE SETTINGS T ABLE B.4 SUMMAR Y OF WELDING PROCESSES FOR RANGER 300 D CONTROL CABLE & DIAGRAM IDLE MODE OUTPUT CONTROL SWITCH ELECTRODE WHEN NOT WELDING TO START WELDING PROCESS STICK - CC CARBON ARC GOUGING - CC TIG - CC K930-1 TIG MODULE / K936-1 CONTROL CABL[...]

B-13 OPERA TION B-13 AUXILIAR Y POWER The Ranger 300 can provide up to 12,000 watts of 120/240 volts AC, Single phase 60 HZ power for con- tinuous use. The front of the machine includes three receptacles for connecting AC power Plugs, one 50 amp 120/240 volt NEMA 14-50R receptacle and two 15 amp 120 volt NEMA 5-15R receptacles. Do not connect any p[...]

B-14 OPERA TION B-14 120/240 VOL T DUAL VOL T AGE RECEPT ACLE The 120/240 volt receptacle can supply up to 50 amps of 240 volt power to a two wire circuit, up to 50 amps of 120 volt power from each side of the three wire cir- cuit, (up to 100 amps total). Do not connect the 115 volt circuits in parallel. Current sensing for the auto- matic idle fea[...]

C-1 ACCESSORIES C-1 GENERAL OPTIONS / ACCESSORIES The following options/accessories are available for your RANGER 300 from your local Lincoln Distributor. K953-1 Two-Wheeled Trailer - For in-plant or yard towing of the RANGER 300. Suitable for road towing with optional Fender and Light Kit. Load capacity is 2,100 lbs. K802-R Power Plug Kit - Provid[...]

C-2 ACCESSORIES C-2 SEMIAUT OMA TIC FCA W AND MIG WELDING (RANGER 300 D) OPTIONS / ACCESSORIES LN-25 Wire Feeder - The recommended wire feeder for use with the Ranger 300 D is the K449 LN-25. This portable unit provides CC/CV for flux-cored arc welding (FCAW) and metal inert gas welding (MIG). for remote control use either a K857 Remote Control Kit[...]

D-1 MAINTENANCE D-1 KUBOT A ENGINE MAINTENANCE SCHEDULE T ABLE D.1 (1) Replace air filter element after 600 hours of operation or sooner under dusty operating conditions. (2) If the engine is operated under heavy load, in high ambient temperatures, or under dusty conditions, change the oil and oil filter every 100 hours. Refer to your Kubota Operat[...]

D-2 MAINTENANCE D-2 ROUTINE AND PERIODIC ENGINE MAINTENANCE To prevent the engine from accidentally starting, dis- connect the negative battery cable before servicing the engine. ------------------------------------------------------------------------ See Table D.1 for a summary of maintenance inter- vals for the items listed below. More frequent s[...]

D-3 MAINTENANCE D-3 FUEL At the end of each day ’ s use, refill the fuel tank to minimize moisture condensation and dirt contami- nation in the fuel line. Do not overfill; leave room for the fuel to expand. Use only fresh, No. 2 grade DIESEL fuel. Do not use kerosene. See the Kubota Engine Operator's Manual for instruc- tions on replacing th[...]

D-4 MAINTENANCE D-4 Always premix the antifreeze and clean tap water before adding to the radiator or the overflow tank. It is very important that a precise 50/50 solution be used with this engine year round. This gives proper cooling during hot weather and freezing protection to -34 ° F (- 37 ° C). Cooling solution exceeding 50% ethylene glycol [...]

D-5 MAINTENANCE D-5 CHARGING THE BATTERY When you charge, jump, replace, or otherwise con- nect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The RANGER 300 positive (+) battery termi- nal has a red terminal cover. If you need to charge the battery with an external charger, discon[...]

E-1 TROUBLESHOOTING E-1 RANGER 300 D AND 300 DLX If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION W ARNING ELECTRIC SHOCK can kill. • Do not touch electrica[...]

E-2 TROUBLESHOOTING E-2 RANGER 300 D AND 300 DLX Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTIO[...]

E-3 TROUBLESHOOTING E-3 RANGER 300 D AND 300 DLX Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTIO[...]

E-4 TROUBLESHOOTING E-4 RANGER 300 D AND 300 DLX Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTIO[...]

F-1 CONNECTION DIAGRAMS F-1 RANGER 300 D AND 300 DLX (RANGER 300 DLX ONLY) 6 PIN AMPHENOL TO WORK 14 PIN AMPHENOL LN-25 N.E. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED. N.C. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL REMOTE SWITCH IN "REMOTE" POSITION. 6-20-97 S23732-1 ELECTRODE CABLE WIRE FEEDE[...]

CONNECTION DIAGRAMS F-2 F-2 RANGER 300 D AND 300 DLX ELECTRODE TO WORK 14 PIN TO WORK AMPHENOL N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO A WIRE WELDING-CV POSITION. WARNING Keep guards in place. or service this equipment. Keep away from moving parts. Only qualified personnel should install,use CONT[...]

CONNECTION DIAGRAMS F-3 F-3 RANGER 300 D AND 300 DLX CAUTION : or service this equipment. Keep away from moving parts. Keep guards in place. ELECTRODE TO WORK TO LN-742 INPUT CABLE PLUG 14 PIN K592 CONTROL CABLE AMPHENOL ELECTRODE CABLE TO WORK TO WIRE FEED UNIT N.E. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRE[...]

CONNECTION DIAGRAMS F-4 F-4 RANGER 300 D AND 300 DLX Keep away from moving parts. 31 NOT USED ON RANGER POWER SOURCES 42 TO WIRE FEED UNIT ELECTRODE CABLE ADAPTER PLUG K867 UNIVERSAL Only qualified personnel should install,use 82 41 81 Do not touch electrically live parts. 4 2 SPARE 6-20-97 S23732-7 CAUTION : N.D. FOR WIRE FEEDERS THAT RETURN A SIG[...]

CONNECTION DIAGRAMS F-5 F-5 RANGER 300 D AND 300 DLX 14 PIN AMPHENOL ELECTRODE 6-20-97 K963-1 HAND AMPTROL -OR- S23732-9 -OR- K814 ARC START SWITCH K870 FOOT AMPTROL N.B. USE POLARITY SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO A "STICK/WELD" POSITION. DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FA[...]

CONNECTION DIAGRAMS F-6 F-6 RANGER 300 D AND 300 DLX N.D. CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TO WORK EXTENDED #21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD. N.G. TAPE UP BOLTED CONNECTION WHERE LEAD #21 IS EXTENDED. N.E. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE FOR THE INST[...]

F-7 WIRING DIAGRAM F-7 RANGER 300 D AND 300 DLX 5A 221 INDICATES JACK NUMBER 5 1 CAPACITORS 236A OUTPUT 4 RECTIFIER 5A _ C2 (-) A2 + 245 DC+ 232 R4 R3 W7 224 224C C1 3B WHITE 3F 11 3A 15A BLACK BLACK 12 BLACK BLACK WHITE 120/240V J8 BLACK BLACK BLACK BLACK BLACK BLACK CB7 3D (15AMP) SWITCH A1 210 W14 S2A (CLOSED POSITION) 219 32 GND-C 9 10J10 SWITC[...]

F-8 WIRING DIAGRAM F-8 RANGER 300 D AND 300 DLX 67 75A 3C PCB2 BYPASS PC 4 1 76B 2 J10 227 76A 5E 4 BLACK BLACK 11 RECEPTACLE 3B 125/250V. SINGLE BLACK BLACK BLACK BLACK 3F 3A 3B 201 B 1J10 2J10 222B 225 223 3J10 HIGH GLOW PLUG GLOW PLUGS FLASHING CURRENT 5 AC 9 15A 50A 77B 201 CB2 75B 3 CB7 15A J10 5 W4 254 TERMINALS 5L GREEN GND-C 5H ENGINE GROUN[...]

F-9 WIRING DIAGRAM F-9 RANGER 300 D AND 300 DLX NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equ[...]

F-10 DIMENSION PRINT F-10 RANGER 300 D AND 300 DLX 30.50 6-20-97 13.00 33.81 60.18 13.85 18.48 6.75 34.86 20.25 12.36 60.50 17.37 18.00 11.98 6.26 M18399 L 18.00 31.00 46.08 C RADIATOR CAP CENTER OF GRAVITY .24 2.70 9.96 24.04 24.75 DIMENSION PRINT - RANGER 300[...]

NOTES RANGER 300 D AND 300 DLX[...]

NOTES RANGER 300 D AND 300 DLX[...]

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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

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